HIL TESTING OF A MODERN DRILLING RIG. Using Simulink as modelling tool

Transcription

1 HIL TESTING OF A MODERN DRILLING RIG Using Simulink as mdelling tl Marine Cybernetics

2 SOFTWARE IS FANTASTIC Sftware allws us t design, build and perate amazing machines. Sftware allws us t plan and cnduct extremely cmplex missins. Sftware has changed the way we live.

3 SOFTWARE IS EVERYWHERE In yur hand phnes, pads, gadgets, In yur hme cmputers, kitchen appliances, steres, TVs, smart devices, In critical infrastructure pwer distributin, water, sewage, banks, telecmmunicatin, finance, health care, the internet, In transprtatin planes, cars, ships,

4 SOFTWARE VS HARDWARE -Eh, can yu make it 3 feet wider?

5 SOFTWARE VS HARDWARE Class Bridge private duble width = 60; private duble length = 4500; public vid tilttwers45degrees(); - Sure, n prblem. Change the length als?

6 SOFTWARE IS FRAGILE

7 WHEEL HOUSE

8 SOFTWARE ON A DRILLING RIG IS A CHALLENGE Pwer management system Dynamic psitining system Thruster cntrl system Crane cntrl system s f I/O High cnfigurability 1000 s f functins Integrated autmatin system Drill flr cntrl system OS, Firmware, Applicatins, Netwrk, ++ Many vendrs Emergency shutdwn system Well cntrl systems BOP cntrl system Ballast cntrl system

9 MODERN WHEEL HOUSE

10 WHY DO SOFTWARE ERRORS OCCUR? SW is written by humans, and humans make errrs Mst cntrl system sftware deliveries are unique and tailr-made (cnfigured) fr the vessel A lt f SW functins and cnfiguratin is written under a tight time schedule and finished late in the prjects Cntrl systems are cmplex with many signals and interfaces Integratin f systems frm different vendrs is challenging and errr-prne Frequent updates and patches intrduce new prblems Difficult t accunt fr all peratinal scenaris, failures and situatins that may ccur at the design stage

11 WHAT IS HIL TESTING?

12 I/O I/O HIL TESTING VIRTUAL TEST ENVIRONMENT Nrmal peratin Cmmanded thrttle Cruise cntrller Speed measurement HIL testing Cruise cntrller Cmmanded thrttle Simulated speed measurement

13 I/O I/O HIL TESTING VIRTUAL TEST ENVIRONMENT Nrmal peratin Cmmands DP system Measurements HIL testing DP system Cmmands Simulated measurements

14 HIL TESTING OF CONTROL SYSTEMS SIMULATES SCENARIOS WHICH OCCUR DURING OPERATIONS Types f testing: 1. Functinal testing t see if the target system sftware and hardware wrk as specified. 2. Failure testing t check if the cntrl system sftware and hardware is sufficiently resilient t relevant failure situatins. 3. Perfrmance testing t see if the cntrl system is tuned t perfrm with sufficient accuracy if requested.

15 COMPANY HISTORY Identifying sftware issues: 2012 BOP-HIL launched Reducing risk fr incidents and accidents Reducing risk fr ff-hire and nnprductive time Securing safe and reliable peratins Securing flawless startups 2010 Integratin Testing f Maritime systems DrillMAX ICE 2009 Drill-HIL f Maersk Discverer Safe sftware safe peratin 2008 SPT-HIL pilt with ABB 2006 PMS-HIL f Burbn Mistral and Burbn Mnsn 2004 DP-HIL f Viking Vanquish 2002 Marine Cybernetics funded

16 HOW TO CREATE A HIL TEST APPLICATION?

17 CHOSE AN EXCELLENT MODELING PLATFORM Marine Cybernetics has fr 13 years perfrmed all mdeling in Simulink. We are currently using M2013b. Marine Cybernetics has abut 40 emplyees that daily use the fllwing Mathwrks prducts: MATLAB Simulink Simulink cder Embedded Cder We have been self-ging, but have very gd experience with the supprt team at Mathwrks.

18 HIL SIMULATION MODELS CREATED WITH SIMULINK Hydrdynamics 6DOF vessel mtin Wave, wind current lads Ice lads Prpulsin Azimuths, pds, tunnels, main prps, rudders, Thrust lsses and Interactins External lads Mring Hawsers Pipe laying Plughing Risers Streamer Pwer system Pwer generatin/ distributin Lad limitatin Buses and breakers Drilling system Draw wrk Tp drive Pipe racker Rughneck Heave cmp... Sensrs DGPS HPR Artemis Gyrs VRU Wind sensrs Envirnment Wind Current Waves Ice Failure mdes Inherent electr/ mechanical Signal failures Main benefits f mdeling in Simulink: Quickly evaluate yur mdel and validate the simulatin results. Vast library f standard Simulink blcks available ut the bx. Lw level prgramming skills nt needed. Self-dcumenting if used right. Cde generatin rcks!

19 AUTOMATIC CODE GENERATION WITH EMBEDDED CODER C++ cde is generated frm Simulink mdels by the Embedded Cder. A PC 32-bit target platfrm is used (Windws). Embedded Cder can generate a C++ class interface t mdel cde. Marine Cybernetics adds a Java Native Interface wrapper t the generated C++ cde. Cntrl ver access t mdel data Ability t multiply instantiate mdel classes Easy integratin f mdel cde int C++ prgramming envirnments

20 BRIDGING SIMULINK AND JAVA The JNI cde implements a defined Java Interface s that any Simulink mdel will structurally lk the same fr the calling Java applicatin. Example f interface methds: initialize step terminate setparameter setinputsignal getoutputsignal Simulink and cde generatin is a pwerful tl fr generating mdels that can be incrprate in a generic sftware envirnment. Fr Marine Cybernetics it has been a great success t be able t cmbine a strng mdelling team with dedicated sftware develpers. This has been pssible due t: Autmatic cde generatin Clear system bundaries and respnsibilities

21 CYBERSEA HIL SIMULATOR PLATFORM CyberSea is designed t bridge the gap between physical mdeling and applicatin develpment. Autmates fundamental parts in the prcess f building full-blwn HIL test applicatins frm simulatin mdels. Includes generic GUI functinality and cnfiguratin tls. Includes imprtant HIL features such as built-in signal failure mdes, lgging, trending, scenari management and web interface. Includes an extensive library f I/O interfaces fr cmmunicatin between HIL simulatrs and cntrl systems. CyberSea includes a generic framewrk fr desktp applicatins. It prvides functinality fr saving state, cnnecting actins t menu items, tlbar items and keybard shrtcuts, and windw management.

22 POWER PLANT SIMULATOR

23 VESSEL SIMULATOR

24 UTILIZING 3D VISUALIZATION IN HIL TESTING 3D graphics is a pwerful tl when perfrming HIL testing f drillflr systems Hwever; The mst imprtant is the simulatr Simulink mdels running in the backgrund and the HIL framewrk

25 ANTI-COLLISION / ZONE MANAGEMENT SYSTEM: EXAMPLES OF TARGETED FUNCTIONS Mnitring Alarm and messaging functinality Prevent machine frm entering ther machines zne Stp machine if ther machine is entering the zne Anti-cllisin release Anti-cllisin ignre Stp f machines n nn-healthy psitin data Cmpliance t dcumentatin 2012 Marine Cybernetics

26 EXAMPLES OF TEST FACILITIES 2012 Marine Cybernetics

27 REMOTELY LOCATED PC S FOR MACHINE SIMULATION AND 3D VISUALIZATION

28 CYBERSEA SIGNATURE

29 141 NEW BUILDINGS/RETROFITS 28 Platfrm Supply Vessels (PSV) 15 Anchr Handling Tug Supply (AHTS) 6 Emergency Rescue Recvery Vessels (ERRV) 23 Offshre Cnstructin Vessels ROV, Diving, IMR, Well interventin 56 Drilling units (semi/drillship/jack-up) 1 Seismic Vessel 12 Shuttle Tankers

30 CONCLUSION HIL testing is an excellent verificatin methd fr cntrl systems Chse the right tls fr the different jbs

31 Marine Cybernetics